Three-Dimensional Scanning Device, and Scanning-Based Modeling Method Implemented by the Same

This application claims priority to Taiwanese Invention patent application No. 113141333, filed on Oct. 29, 2024, the entire disclosure of which is incorporated by reference herein.

The disclosure relates to a three-dimensional (3D) scanning device and a scanning-based modeling method, and more particularly to a 3D scanning device and a scanning-based modeling method that are adapted for reverse engineering.

3D reverse scanning devices are generally categorized into two main types: contact-based measurement and non-contact measurement. Scanning modules of contact-based measurement primarily use mechanical probes or other physical contact methods to measure a surface of an object through direct contact. This method is commonly used in industries such as manufacturing, engineering, and scientific research for dimensional measurements. The contact-based measurement is suitable for measuring small to medium-sized mechanical and hardware components, including surface dimensions (to verify compliance with tolerances), simple 2D and 2.5D shapes, and basic external contours. For measuring large components or products with complex 3D surfaces, non-contact 3D scanning devices are typically used. These devices rely on machine vision components such as LiDAR or radar instead of physical contact. Using techniques like structured light scanning, laser scanning, and infrared scanning through optical lenses, data of reflected light are captured to reconstruct a 3D computer aided design (CAD) model of the object. Non-contact measurement is particularly suited for reverse engineering in automotive and machinery industries, allowing precise measurement of complex geometries and dimensions of existing components. The resultant 3D models can be used for replicating external shapes and dimensions or for design modifications and improvements.

Common non-contact 3D scanning devices come in various types, including handheld, benchtop, and machine-mounted models. Small handheld scanners are lightweight, portable, and relatively affordable, but have limitations in measurement range, dimensional accuracy, and suitability for scanning large objects. In contrast, benchtop and machine-mounted scanners offer high precision and capability to rapidly scan large objects, but are stationary and cannot be easily transported for on-site use. Additionally, these systems are more expensive, require trained professionals to operate, and thus are suited for use in dedicated, controlled environments rather than field applications.

Therefore, an object of the disclosure is to provide a 3D scanning device that can alleviate at least one of the drawbacks of the prior art.

According to the disclosure, the 3D scanning device, includes a shell, a distance measuring module, a scanning platform, a control module, and a power source module. The shell surrounds and defines an accommodating space, and is operable to open or close for a purpose of allowing access to or sealing the accommodating space. The distance measuring module includes a bracket that is detachably mounted on the shell, and a plurality of optical rangefinders that are mounted to the bracket. Each of the plurality of optical rangefinders is configured to project light including at least one of laser, infrared or structured light, and to capture reflection of the light thus projected. The scanning platform includes a stepper motor that is disposed in the accommodating space, and a support base that is configured to be rotated by the stepper motor with a rotation axis perpendicular to a top surface of the support base. The control module is disposed in the accommodating space and is communicatively connected to the plurality of optical rangefinders and the stepper motor. The power source module is disposed in the accommodating space, and is configured to provide electric power to the plurality of optical rangefinders, the stepper motor, and the control module.

Another object of the disclosure is to provide a scanning-based modeling method that is implemented by the 3D scanning device of the disclosure.

According to the disclosure, the scanning-based modeling method includes a scanning step and a converting step. In the scanning step, the plurality of optical rangefinders perform scanning on an object to collect multiple point datasets of the object respectively at multiple angles relative to the object, and the distance measuring module transmits the multiple point datasets to a processing system. In the converting step, the processing system converts the multiple point datasets into three-dimensional coordinates, and constructs a complete model of the object based on the three-dimensional coordinates.

Yet another object of the disclosure is to provide a scanning-based modeling method that is implemented by multiple 3D scanning devices of the disclosure.

According to the disclosure, the scanning-based modeling method includes a preparing step, a scanning step, and a converting step. In the preparing step, the plurality of three-dimensional scanning devices are arranged around an object at different angles relative to the object, and the plurality of three-dimensional scanning devices are spaced apart from each other. In the scanning step, the plurality of optical rangefinders of the plurality of three-dimensional scanning devices perform scanning on the object to collect multiple point datasets of the object respectively from the plurality of three-dimensional scanning devices, and the distance measuring modules of the plurality of three-dimensional scanning devices transmit the multiple point datasets to a processing system. In the converting step, the processing system converts each of the multiple point datasets into three-dimensional coordinates, constructs a local model of the object based on the three-dimensional coordinates for each of the multiple point datasets, and combines the local models respectively constructed for the multiple point datasets to form a complete model of the object.

Before the disclosure is described in greater detail, it should be noted that where considered appropriate, reference numerals or terminal portions of reference numerals have been repeated among the figures to indicate corresponding or analogous elements, which may optionally have similar characteristics.

It should be noted herein that for clarity of description, spatially relative terms such as “top,” “bottom,” “upper,” “lower,” “on,” “above,” “over,” “downwardly,” “upwardly” and the like may be used throughout the disclosure while making reference to the features as illustrated in the drawings. The features may be oriented differently (e.g., rotated 90 degrees or at other orientations) and the spatially relative terms used herein may be interpreted accordingly.

1 3 FIGS.to 1 2 3 4 5 2 3 4 5 1 1 11 12 11 11 11 111 1 11 111 2 3 4 5 11 Referring to, an embodiment of a 3D scanning device according to this disclosure is shown to be in an expanded state, and includes a shell, a distance measuring module, a scanning platform, a control moduleand a power source module, where the distance measuring module, the scanning platform, the control moduleand the power source moduleare mounted on the shell. The shellincludes two box-shaped compartmentsthat are pivotally connected to each other via, for example, one or more hinges, and a folding jointthat is detachably mounted on one of the compartments. The compartmentsare operable to open or close. When being closed, the compartmentscooperatively surround and define an accommodating spacethat is sealed by the shell. When the compartmentsare opened, access to the accommodating spaceis allowed. In the illustrative embodiment, the distance measuring module, the scanning platform, the control moduleand the power source moduleare mounted on the same compartment, but this disclosure is not limited in this respect.

2 21 12 22 21 12 21 21 211 12 212 211 1 21 211 212 211 21 12 21 212 211 211 22 212 22 212 211 1 3 FIGS.through 4 5 FIGS.and The distance measuring moduleincludes a bracketthat is detachably mounted on the folding joint, and multiple (two in the illustrative embodiment) optical rangefindersthat are mounted on the bracket. The folding jointallows the bracketto be folded or unfolded. The bracketincludes a postmounted on the folding joint, and two extending armsconnected to the postthrough a folding mechanism, such as a joint mechanism. When the shellis opened and the bracketis in an unfolded position as shown in, the postextends upward and is perpendicular to a horizontal plane, and the extending armsextend laterally and oppositely from the post(i.e., extend in opposite horizontal directions that are parallel to the horizontal plane). The bracketis foldable from the unfolded position to a folded position through the connection with the folding joint, as shown in. When the bracketis in the folded position, the extending armsare folded relative to the postand rest parallel to the post. Each of the optical rangefindersis mounted on a respective one of the extending arms, and is configured to project light that is one of laser, infrared or structured light, and to capture reflection of the light thus projected. In some embodiments, there may be more than two optical rangefindersmounted on the extending armsand/or even the post, and this disclosure is not limited in this respect.

1 3 FIGS.to 3 31 11 111 32 31 111 33 32 33 31 32 33 33 4 111 22 32 5 111 22 32 4 Referring to, the scanning platformincludes an adjusting framethat is detachably mounted on the corresponding compartmentand that is disposed in the accommodating space, a stepper motorthat is mounted on the adjusting frameand that is disposed in the accommodating space, and a support basethat is detachably mounted on and rotatable by the stepper motor, with a rotation axis perpendicular to a top surface of the support base. The adjusting frameis operable to raise or lower the stepper motorand the support base, thereby adjusting a height of the top surface of the support base. The control modulemay include, for example, a microcontroller, and is disposed in the accommodating spaceand communicatively connected to the optical rangefindersand the stepper motor. The power source modulemay include, for example, a battery module and/or a converter module, and is disposed in the accommodating spaceand connected to the optical rangefinders, the stepper motorand the control modulefor providing electric power thereto.

1 3 FIGS.through 4 5 FIGS.and 212 211 211 21 211 211 33 32 31 3 111 11 111 2 3 33 4 5 111 1 11 12 3 4 5 When the 3D scanning device is to be shifted from an expanded state (see) to a stowed state (see), the first action is to fold the extending armsto make them parallel to the post, and then the postis folded to make the bracketswitch from the unfolded position (where the postis perpendicular to the horizontal plane) to the folded position (where the postis parallel to the horizontal plane). Subsequently, the support baseis detached from the stepper motor, and the adjusting frameis lowered, thereby ensuring that the scanning platformcan be stowed in the accommodating space. Then, the compartmentsare closed to seal the accommodating space, so that the distance measuring module, the scanning platform(including the detached support base), the control module, and the power source moduleare received in the accommodating space. In some embodiments, the shellmay be designed to have a handle or other features for easy carrying, allowing users to conveniently transport the 3D scanning device. In some embodiments, a mounting plate (not shown) with multiple mortises may be provided on one of the compartments, and the folding joint, the scanning platform, the control module, and the power source moduleare inserted into these mortises using tenon-and-mortise connections.

1 3 6 FIGS.,and 61 62 63 61 33 31 33 33 62 32 33 22 2 63 Referring to, the 3D scanning device of this disclosure may be used in various ways to implement scanning-based modeling, which includes a preparing step, a scanning stepand a converting step. In the preparing stepof the first implementation, a small-sized object (not shown) that serves as a modeling target is placed on the top surface of the support base, and the adjusting frameis operated to raise or lower the support baseto make the top surface of the support basepositioned at a desired height. In the scanning stepof the first implementation, the stepper motordrives the support baseto rotate for one or more full revolutions, during which the optical rangefindersscan the object to continuously collect multiple point datasets of the object respectively at multiple angles relative to the object; and the distance measuring moduletransmits the point datasets to a processing system (e.g., a computer system, not shown). In the converting stepof the first implementation, the processing system may select and convert some of the point datasets that respectively correspond to some specific angles or all of the point datasets into 3D coordinates, and construct a complete model of the object based on the 3D coordinates.

33 61 62 61 211 12 2 11 21 62 21 21 22 22 63 The second implementation of the scanning-based modeling is suitable for a larger object (e.g., too large to be placed on the support base) that serves as the modeling target, and has different preparing stepand scanning stepfrom the first implementation. In the preparing stepof the second implementation, the postis detached from the folding joint, so as to separate the distance measuring modulefrom the compartmentsfor a person to use his/her hand or a movable machine (e.g., a robot, a vehicle, etc.) to hold the bracket. In the scanning stepof the second implementation, the person or the machine that holds the bracketmoves the bracketalong with the optical rangefindersaround the object for one or more full revolutions, during which the optical rangefindersscan the object, thereby collecting multiple point datasets of the object respectively at multiple angles relative to the object. The second implementation has the same converting stepas the first implementation to construct a complete model of the object, so details thereof are not repeated for the sake of brevity.

61 62 22 2 63 The third implementation of the scanning-based modeling is implemented using a plurality of the 3D scanning devices according to this disclosure, and is suitable for an even larger object that serves as the modeling target. In the preparing stepof the third implementation, the 3D scanning devices are arranged around an object at different angles relative to the object. In some embodiments, the 3D scanning devices are arranged at equal angular intervals in an annular pattern around the object. In the scanning stepof the third implementation, the optical rangefindersof each of the 3D scanning devices scan the object at a corresponding angle relative to the object, so that the 3D scanning devices collect multiple point datasets of the object respectively at multiple angles relative to the object. Then, the distance measuring modulesof the 3D scanning devices transmit the point datasets to the processing system. In the converting stepof the third implementation, the processing system may select and convert some of the point datasets that respectively correspond to some specific angles or all of the point datasets into 3D coordinates, and construct a local model of the object based on the 3D coordinates for each of the selected point datasets. Then, the processing system combines the local models that are respectively constructed for the selected point datasets into a complete model of the object.

2 3 4 5 111 1 111 3 21 22 1 21 To sum up, in the embodiment of this disclosure, the distance measuring module, the scanning platform, the control moduleand the power source modulecan be stored in the accommodating space. When the shellis closed to seal the accommodating space, the 3D scanning device is stowed as a suitcase, thereby achieving high portability and flexibility. When the object that serves as the modeling target is not large, the object can be placed on the scanning platformfor scanning and modeling. When the object is large, the bracketthat is equipped with the optical rangefinderscan be detached from the shell, and the scanning can be performed by a person or a movable machine holding the bracketand moving around the object. In an alternative approach, multiple 3D scanning devices can be arranged around the object at different angles relative to the object to scan local appearances of the object, respectively, and then the local appearances are integrated into a complete 3D model of the object through merging and stitching. Accordingly, the embodiment of this disclosure is adapted to modeling targets of various sizes, and thus offers greater versatility.

In the description above, for the purposes of explanation, numerous specific details have been set forth in order to provide a thorough understanding of the embodiment(s). It will be apparent, however, to one skilled in the art, that one or more other embodiments may be practiced without some of these specific details. It should also be appreciated that reference throughout this specification to “one embodiment,” “an embodiment,” an embodiment with an indication of an ordinal number and so forth means that a particular feature, structure, or characteristic may be included in the practice of the disclosure. It should be further appreciated that in the description, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of various inventive aspects; such does not mean that every one of these features needs to be practiced with the presence of all the other features. In other words, in any described embodiment, when implementation of one or more features or specific details does not affect implementation of another one or more features or specific details, said one or more features may be singled out and practiced alone without said another one or more features or specific details. It should be further noted that one or more features or specific details from one embodiment may be practiced together with one or more features or specific details from another embodiment, where appropriate, in the practice of the disclosure.

While the disclosure has been described in connection with what is(are) considered the exemplary embodiment(s), it is understood that this disclosure is not limited to the disclosed embodiment(s) but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.